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Petroleum Development Oman


L.L.C.
SP-1173 - WELDING OF METALS
(AMENDMENTS/SUPPLEMENTS TO DEP30.10.60.18)

Document ID SP-1173

Document Type Specification

Security Unrestricted

Discipline Materials & Corrosion

Owner Head of Materials Integrity - UEOC

Issue Date January 2016

Version 1.5

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither
the whole nor any part of this document may be disclosed to others or reproduced, stored
in a retrieval system, or transmitted in any form by any means (electronic, mechanical,
reprographic recording or otherwise) without prior written consent of the owner.

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i Document Authorisation
Authorised For Issue - January 2016

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ii Revision History
The following is a brief summary of the 5 most recent revisions to this document. Details of
all revisions prior to these are held on file by the issuing department.

Version No. Date Author Scope / Remarks


Version 1.1 04/06/2000 OTT/15 Revision and re-formatting of original issue of ERD 43-01.
Version 1.2 25/12/2004 TTO/15 Appendix D added, minor textual corrections.
Version 1.3 11/05/2008 UEC/111 Updated based on past experience
Version 1.4 16/9/2012 UEOC15 Complete rewrite, based on DEP 30.10.60.18-Gen
Version 1.5 17/01/16 UEOC15X Complete rewrite, Amendment to DEP 30.10.60.18-Gen

iii Related Business Processes


Code Business Process (EPBM 4.0)
CP-117 Project Engineering Code of Practice

iv Related Corporate Management Frame Work (CMF)


Documents
The related CMF Documents can be retrieved from the Corporate Business Control
Documentation Register CMF.

Doc. ID Document Title


SP-1171 Specification for Quality Assurance Requirements for Product and
Service
SP 1176 Non-Destructive Examination ( Amendments/Supplements to ASME BPV
Code section V)
DEP-30.10.60.18-Gen Welding of metals (amendments/supplements to API RP 582)
DEP 30.10.60.31-Gen Oxidation of stainless steel weldments
DEP 31.10.00.10-Gen Material traceability and positive material identification (PMI)
DEP 31.38.01.31-Gen Shop and field fabrication of piping
DEP 31.38.01.31-Gen Unfired pressure vessels
Selection of materials for life cycle performance (upstream equipment)
DEP 39.01.10.12-Gen
including H2S-containing environments
(Amendments and supplements to ISO 15156:2009)
Metallic Materials – Prevention of Brittle Fracture in New Assets
DEP 30.10.02.31-Gen.
Equipment Criticality in Pressure Vessel Design
DEP 31.22.00.30-Gen.

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TABLE OF CONTENTS
i Document Authorisation ....................................................................................................... 3
ii Revision History ................................................................................................................... 4
iii Related Business Processes ............................................................................................... 4
iv Related Corporate Management Frame Work (CMF) Documents ...................................... 4
PART I INTRODUCTION .................................................................................................................. 6
1.1 SCOPE ................................................................................................................................. 6
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ................... 6
1.3 DEFINITIONS....................................................................................................................... 6
1.4 CROSS-REFERENCES ....................................................................................................... 6
1.5 SUMMARY OF MAIN CHANGES ........................................................................................ 6
Part II GENERAL ............................................................................................................................ 7
2.5 INSPECTION PERSONNEL ................................................................................................ 7
2.6 EQUIPMENT ........................................................................................................................ 7
Part III AMENDMENTS/SUPPLEMENTS TO DEP 30.10.60.18- VERSION 2015.......................... 7
4 GENERAL WELDING REQUIREMENTS ............................................................................ 7
4.5 SPECIAL CONDITIONS ...................................................................................................... 7
4.6.1 WELDING PROCEDURE SPECIFICATIONS (WPSs) ................................................................. 7
4.6.2 WELDING PROCEDURE QUALIFICATIONS ..................................................................... 8
4.6.3 WELDER QUALIFICATION ................................................................................................. 8
4.6.4 PREPARATIONS FOR WELDING.................................................................................... 9
4.8 AFTER WELDING ................................................................................................................ 9
4.9 PRESSURE BOUNDARY WELDS ...................................................................................... 9
5 WELDING PROCESSES ..................................................................................................... 9
5.2 LIMITATIONS OF FUSION WELDING PROCESSES ......................................................... 9
6 WELDING CONSUMABLES (FILLER METALANDFLUX) ................................................ 10
6.1 GENERAL .......................................................................................................................... 10
7 SHIELDING AND PURGING GASES ................................................................................ 10
8 PREHEATING AND INTERPASS TEMPERATURE ......................................................... 10
9 POST WELD HEAT TREATMENT (PWHT) ...................................................................... 10
11 SPECIAL PROCEDURE QUALIFICATION REQUIREMENTS/TESTING ........................ 11
12.6 HARDNESS TESTING-WELD PROCEDURE QUALIFICATION AND
PRODUCTION TESTING........................................................................................................................11
Annex B (normative) Weld Overlay and Clad Restoration (Back Cladding) ......................... 11
Annex C (normative) Carbon Steel Welding .......................................................................... 13
Annex E (normative) Stainless Steel Welding ....................................................................... 13
Annex K (normative) Dissimilar Welding ............................................................................... 14

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PART I INTRODUCTION
1.1 SCOPE
This specification (SP) specifies requirements and gives recommendations for welding of
metals. These specifications amend/supplements requirements of DEP 30.10.60.18-Gen
2015. All clauses of DEP 30.10.60.18-Gen not modified by this SP remain valid as written.
This is a revision of the SP of the same number dated February 2012 and has undergone
total change.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY


CONSIDERATIONS

Unless otherwise authorised by PDO, the distribution of this SP is restricted to Contractors


and Manufacturers/Suppliers nominated by PDO. Any authorized access to this SP does
not constitute an authorization to any documents, data or information to which the SP
refers.
This SP is intended for use in facilities related to oil and gas production, gas handling, and
distribution.

1.3 DEFINITIONS

1.3.1 General definitions


Add the following:
In the context of this SP, Principal means CFDH Materials Integrity of the Company.

1.4 CROSS-REFERENCES

Where cross-references to other parts of this SP are made, the referenced section number
is shown in brackets ( ). Other documents referenced by this SP are listed in (Part IV).

1.5 SUMMARY OF MAIN CHANGES

This SP is a revision of the SP of the same number dated 2012 and has undergone a
complete re-write.

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Part II GENERAL
2.5 INSPECTION PERSONNEL

Add the following to the table in bullet point 2:

Welding AWS-CWI or CSWIP 3.1/3.2

For NDE/NDT requirements refer to SP 1176.

2.6 EQUIPMENT

Add the following note at the end of this clause.

Note: Critical equipment means:


1. Pressure vessels classified as category 1 or 2 in accordance with DEP
31.22.00.30-Gen.
2. Process piping in sour service.
3. Process piping when MDMT is below -29 degree C.

Part III AMENDMENTS/SUPPLEMENTS TO DEP 31.22.00.31-Gen


4 General Welding Requirements
4.1
Add the following at the end of this clause:
4.1.5 This specification and DEP 31.10.60.18-Gen. are not applicable for the
following:
 Air receivers, utility lines, lube oil lines, gear-boxes, civil
structures, mill products and
 MESC items unless otherwise specified elsewhere.
 Item packages that is proprietary to the manufacturer (i.e.
protected by trade mark or patent or copy right) which are
identified by the Custodian/ CFDH and made of Carbon and
Carbon manganese steels, 300 series austenitic stainless steels.

4.5 Special Conditions

Delete bullet point 1 in this sub clause and replace with the following:
1. Carbon steel equipment and process piping if identified as ‘’sour’’, fabrication
shall meet Annex C requirements of this specification.

4.6.1 Welding Procedure Specifications (WPSs)

4.6.1.1 General
Delete 3rd bullet point and add the following:
3. If PWHT is required for pressure vessels of carbon and carbon manganese
steels including clad vessels, in addition to the code requirements, PQRs
shall be qualified with 2 cycles simulated PWHT.
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4.6.1.3 Previously Qualified Procedures


Delete this sub clause entirely and replace with the following:
1. WPSs previously qualified by the Contractor or by PDO may be submitted for
approval as long as requirements of this specification are met. The WPSs
shall be supported by Welding Procedure Qualification Records (WPQRs)
witnessed by an acceptable independent third party including all test reports.

4.6.2 Welding Procedure Qualifications

4.6.2.1 General
Delete bullet points 1, 2, 3 and 4 of this sub-clause and replace with the following:
1. All welding procedures shall be qualified in accordance with the applicable code
and this specification. For welding of process piping, welding procedures shall be
qualified on pipe only.
2. For the approval of WPSs, relevant PQRs, a Weld Map for Pressure Vessel and
Piping Class for Piping shall be submitted to relevant Company welding TA
approval.
3. For criticality category 1equipment in accordance with DEP 31.22.00.30-Gen.,
weld -o-let type nozzle joints and set-in joints with shell thicknesses greater than
100 mm or tube sheets with strength welded tube joints shall require full size
mock-ups.
4. Production Test Coupon (PTC) shall be welded for each category A and B shell
joints and it may be welded along with the 1st production long seam and circular
seam if different WPS is applied.
PTC may be exempted if ASTM A grade 60 or 65 materials with 0.43% max carbon
equivalent are used, unless required by the design code.
PTC may be exempted if service is non-sour and MDMT of the pressure vessel is >
minus 29 degree C unless required by the design code.
4.6.2.2 Principal or jurisdiction requirements
Delete bullet point 1 of this sub-clause.

4.6.3 Welder Qualification


Delete bullet point 1 and of this sub-clause and replace with the following:
1. All welders shall be qualified to meet the following:
a. All welders and welding operators shall be qualified in accordance
with the construction codes.
b. Welder qualification validity period shall be set to a maximum of
six months, with possibility of extension upon review of welders’
performance records.
c. For field/site work in Oman: welder qualifications shall be witnessed
by the Company welding Inspector.
Delete bullet point 4 of this sub-clause and replace with the following:
4. All welders and welding operators’ performance test coupons shall be
visually examined, radiographed and mechanically tested. Mechanical
testing is only required when GMAW or FCAW processes are used.
Mechanical testing shall include bend testing.

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4.6.4 Preparations for Welding

4.6.4.1 General
Bullet point 4 of this sub-clause: Delete the words “If required by the Principal,”

4.6.4.4 Permitted Weld Details


Delete bullet point 4 (d) of this sub-clause and replace with the following:
4 (d) Addition or deletion of temporary backing strips shall be
considered an essential variable when impact testing is required and for sour
service, the hardness test shall be included at the backing area in the PQR
to demonstrate meeting hardness requirements.

4.8 After Welding

4.8.2.3 Root Repairs


Delete this sub-clause and replace with the following:
1. Where full access permits, weld repairs to the root of a single sided weld may
be carried out from the inside (process wetted side) on carbon steel materials
but repair welding procedure shall be qualified using simulated conditions.
Minimum 2 layers shall be deposited. If inside weld repair is done, then
process wetted side weld shall subject to hardness testing and fluorescent
MT in addition to other NDT as specified in this specification.

4.9 Pressure Boundary Welds

Delete this sub-clause and replace with the following:


1. Welds on equipment pressure boundary shall comply with the applicable
construction code and welding procedure qualified per ASME/BPVC Sec IX
and this SP.

5 Welding Processes
5.2 Limitations of Fusion Welding Processes

5.2.1 General
Add the following to this clause:
1. GTAW shall be used for all passes of DN 50 (NPS 2) and smaller diameters
pipe work
2. GTAW shall be used for root pass of single side pipe butt welds when the
service is designated as sour service unless back side welding is carried out.
3. GMAW shall only be acceptable when applied using mechanised or automatic
processes. Semi-automated processes are not acceptable except for weld
overlay clad restoration.

5.2.3 GMAW-S
e) In the bullet point 1 of this sub-clause read “should be avoided” as “shall
not be used”.
5.2.5 FCAW

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5.2.5.1 Add the following to this clause:


1. FCAW shall not be acceptable when MDMT is < minus 29 degree C
2. FCAW shall not be used for sour.

5.2.5.6 In Bullet points 1a), b), c) of this sub-clause: Read “should” as “shall”.

5.2.9 ESW
Delete bullet point 1 of this sub-clause and replace with the following:
 ESW welding is permissible for overlay applications only and shall be fully
qualified to ASME/BPVC Sec IX and this specification using the same trade
name consumables as those proposed for production welding.
 Single layer weld overlay may be acceptable. Provided a detailed proposal
with more stringent (more than normal) quality control and inspection program
is submitted and demonstrated to the satisfaction of welding TA 1. Thickness
of deposited pass should not exceed 5 mm.

5.2.10 Miscellaneous
Delete bullet point 2 of this sub-clause and replace with the following:
2. Except for root passes, vertical welding shall be "up-hill".

6 Welding Consumables (Filler Metal and Flux)


6.1 General

Delete bullet point 3 of this sub-clause and replace with the following:
3. Synthetic consumables are not acceptable.
6.1.1 Delete bullet point 4 of this sub-clause and replace with the following:
4. Welding consumables shall be purchased from Manufacturing plants,
currently acknowledged by bodies, which independently test consumables,
e.g., Lloyd's Register of Shipping, American Bureau of Shipping and
Det Norske Veritas and used by the fabricator in similar applications for at
least 3 years successfully other wise use PDO approved consumable vendor
approved list..

7 Shielding and Purging Gases


7.8 Delete bullet point 1 of this sub-clause and replace with the following:
1. Welds made in austenitic, nickel and copper-nickel alloys shall have back
purge maintained for root and second passes.

8 Preheating and Interpass Temperature


8.7 Delete bullet point 3 of this sub-clause.

9 Post Weld Heat Treatment (PWHT)


9.17 Delete d),e), and f) of bullet point 1 of this sub-clause and replace with the
following:
Process piping and pressure vessels: Refer to annex C of this specification.

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11 Special Procedure Qualification Requirements/Testing

11.1.4 WPQR Non-Destructive Testing


Modify the 1st line to be read as “the following requirements shall apply:”

11.1.5 Macro Examination


Modify the 1st line to be read as “the following requirements shall apply:”

12.6 Hardness Testing – Weld Procedure Qualification and


Production Testing
12.6.1.3
Delete bullet point 1 a) and replace with the following:
1 a) For sour service environments, all hardness testing and acceptance values shall
conform
to ISO 15156.
Delete bullet point 1 b), c), d), e) and f) of sub-clause 1 and replace with the following:
325 HV10 maximum for ferritic materials in non-sour process conditions.

Annex (normative) B
Weld Overlay and Clad Restoration (Back Cladding)

B.7 Pressure Equipment and Piping Fabricated with Corrosion-Resistant


Overlay, Clad, or Strip Lining
B.7.1 Single and Double Layered Overlay
Add the following at the end of bullet point 1:
Single layer overlay shall be by ESW process only (refer to clause 5.2.9
above).
Add the following at the end of bullet point 5:
Additional essential variables specified in clause C 1.1 of this specification
are also applicable.
Delete 1st sentence of the bullet point 6 of this sub clause and replace with the
below:
Clad repairs after PWHT may be acceptable if repair welding procedure is
qualified meeting the requirements of this annex.
Add the following additional bullet point 8:
8. ENiCrMo-3 or ERNiCrMo-3 electrode or filler shall be used for weld overlay of
nickel alloy 825 and 625 clad pressure vessels. ERNiFeCr-1 filler may be used for
weld overlay of nickel alloy 825 clad piping components, if GTAW or GMAW
welding process is used, otherwise ERNiCrMo-3 shall be used.
The following restrictions shall apply for ENiCrMo-3 or ERNiCrMo-3 electrode or
filler wires:
a. Sulphur < 0.005%
b. Phosphorous < 0.01%
c. Iron < 1%
d. Manganese < 0.5%
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B.7.2 Strip and Sleeve Lining


Delete this sub clause and replace with the below:
Strip and sleeve lining shall not be acceptable.
B.7.5 Additional Requirements for Welding, PWHT, and Inspection of Pipe with
Internal Overlay
B.7.5.3 Welding Processes for Weld Overlay
Add the following:
Semi-automatic GMAW is only acceptable for weld clad restoration. It shall be limited to flat
position:
All clad restoration and repair areas shall be ground flush for UT and PT examination.
UT disbonding test shall be in accordance with ASTM A578 and shall meet the
requirement of Class B of ASTM A578.
B.7.5.4 Welding Consumables
Delete bullet point 1 of this sub-clause and replace with the following:
 Tubular alloy-filled electrodes shall not be used.
B.7.5.12 Impact Tests
Add the following:
Weld overlay shall not be included in the impact specimen but shall include base
material HAZ. Heat Treatment conditions of the base material and the group
number are essential variable when applicable design code requires impact
testing of base material.
Table B.4 Overlay materials and required overlay analysis
REQUIRED ANALYSIS (Note 1,6)
No. of C Max. Cr Ni Mo Fe Max Notes
Overlay Type
layers
PQR PQR PQR PQR PQR
316L (ESW) 1 or 2 0.04 16.0-21.5 8.0-12.0 2.0-3.0 - 2,3
316L 2 0.04 16.0-21.5 10.0-14.0 2.0-3.0 - 2
317L (ESW) 1 or 2 0.04 16.0-21.5 8.0-12.0 3.0-4.0 - 2,3
317L 2 0.04 17.5-21.5 11-14.5 3.0-4.0 - 2
347 (ESW) 1 or 2 0.08 16.0-20.0 8.0 – 12.0 - - 2,3
347 2 0.08 17.5-21.5 8.5-11.5 - - 2
825 2 0.05 19-23 38-46 2.5-3.5 22 min. 4
Alloy 625(ESW) 1 or 2 0.10 18.0-23.5 50-65 7.0-10.0 15 3, 4,5,7
Alloy 625 2 0.10 18.0-23.5 55-65 7.0-10.0 10 4,5,7
Alloy 276 2 0.04 13 - 15 50 - 55 14 - 16 15 4,5,7

NOTES: 1. For production welding chemistry can be taken at the surface as indicated in Annex B
7.1.
2. Modifications with Type 309L such as additions of Mo or Cb to help meet the analysis
requirements for the final layer may be used for the first layer if they were used to
qualify the procedure.
3. Optional 1 layer overlay only if agreed with the TA 1
4. G28 Method A is required for welding procedure qualification and meets the weight
loss requirement of max. 0.9 mm /year
5. A ferricyanide test (ASTM A380, paragraph 7.3.4) must be passed, no free iron is
allowed.
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6. Maximum alloy content to be limited by filler metal specification. Higher values can be
imposed to compensate for micro segregation.
7. G48 Method A is required for welding procedure qualification and shall meet the
weight loss requirement of max. 4.0 gm /meter square and no pitting more than 25
microns when tested at 40 +1/-1 degrees C.

Annex C (normative)

Change the title to read as “Additional requirement for Carbon Steel Welding”.

. C.1 Sour Service


Delete the entire sub clause and replace with the following:

Additional essential variables for Welding Procedure Qualification:

The following additional essential variables shall be applied in addition to ASME


Section IX:
 Any increase in carbon equivalent in base material by more than 0.03
 If Nb or V content in base material is above 0.01%, then any increase in
Nb or V content above the qualified PQR (applicable for pressure vessels
category A and B joints in the shell only)
 Any decrease in heat input by more than 10%
 Any decrease in preheat temperature
 When PWHT is not applied for thicknesses greater than 20 mm PQR
shall be qualified on equal or greater than actual thickness
 Any change in the brand name of the welding consumables
 Any decrease in the bevel angle by more than 5 degrees if included angle
is less than 50 degrees
 Any change in welding process sequence for process side weld if PWHT
is not applied
Add the following clause:

C.1.2 PWHT
a. Above 20 mm, a minimum preheat of 150 degrees C shall be applied
for the Process piping unless PWHT is applied.

Annex E (normative)

Stainless Steel Welding


E.1.3 Weld Procedure Test Requirements
Delete the word “If required by the Principal “in this sub clause.
E.1.4 Essential Variables
E.1.4.2 Welding Process
Delete the word “If required by the Principal “in this sub clause.

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E.2 6Mo super austenitic Stainless Steel


E.2.7 Repair Welding
Bullet points 2, 5, 6 and 7: Read “should “as “shall”

E.6 Duplex Stainless Steel


E.6.2, 3 Qualification of Welding Procedures
Delete bullet point 6 of this sub clause:
E.6.2.4 Hardness Considerations
Add the following at the end of this sub-clause:
If the thickness 5 mm or less, hardness survey shall be at mid thickness only.
If the thickness is 8 mm or less hardness survey required at 2 mm below each
surface.
E.6.2.5 Corrosion and Impact Tests
E.6.2.5.1 General
Delete this sub clause and replace with the following
1. Corrosion and impact tests shall be performed on WPQR specimens and
shall provide satisfactory results. Impact testing is required for wall thickness
6 mm and above unless otherwise required by the design code. The samples
shall be taken at 3 O’clock or 9 O’clock position.
E.6.2.5.2 Corrosion Testing
Delete bullet point 1 of this sub clause.
Bullet point 2: Delete reference to “If required by Principal”.
Delete bullet point 2 (e) and (g) of this sub clause and replace with the following:
The test specimen shall be immersed in ferric chloride solution for 24 hrs
at 22±1 °C for duplex steel and at 35±1 °C (for super duplex steel.
The test acceptance criteria shall be:
i. No evidence of pitting greater than 25 microns examined at a
magnification of X 20.
ii. Weight loss shall not exceed 8g/m 2
E.6.4.5 WPQR Controls
Bullet point 4 of this sub clause: in the last line, Read “should” as “shall” and
replace with the following:

Annex K (normative)
Dissimilar Welding

K.1 General
Delete bullet point 1 and replace with the following:
1. The dissimilar welds between ferritic and austenitic materials for the
following applications/conditions shall be approved by Materials Integrity
TA/1 or shall be stated in “materials selection report (MSR)” developed by
UEOC/1 section.
d. Sour service
e. Hydrogen-charging

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f. High temperature-high hydrogen partial pressure


g. Acid corrosion
h. High temperature
i. Cyclic service

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